Electrical gremlins :(

[Losttheplot]

While out for a ride last weekend, my XChallenge started blowing fuses when i hit the starter button.

The motor would turn over a few times before the 15A fuse would blow, killing the ignition and fuel pump.

If i bump started the bike it would be fine.

It only misbehaved when you pressed the starter button.

I've stripped the plastics off and had a look at the loom, and i can't see any signs of the insulation having worn through.

Also followed the wiring to the starter solenoid and that seems fine also.

The following day after my investigations drew a blank, i wrapped up the loom again and reassembled the bike. After this the problem stopped.

Any suggestions? i'd like to track this and cure it so it doesn't happen again..

nathan

 

[Losttheplot]

Well the gremlins are back

Dug the bike out last night for today's hants/surrey ride out.

Took it for a brief spin last night to get petrol, and after the initial run from the barn to the house it was fine, but after leaving it to get my helmet and gloves, the bike was dead as a dodo.

Apart from the indicator lights on the dash flashing repeatedly, and thats with the ignition off.

Turn the key and absolutely nothing.

I stripped the bike, and pulled all the relays out i could find, blew all the crap out of the joints and reconnected them, and all seemed fine.

Took it out and got petrol, and no problems.

Loaded into the van and onto hindhead this morning, and at the end of the first trail it did exactly the same thing again.

I've stripped the bike again, and still haven't found any damage on the loom.

I see on Advrider that the starter solenoid can give problems similar to my original post, so i'll be changing that.

Has anyone else had problems with their bike? what was the cause?

nathan

 

[ghiribizzo]

The starter solenoid will work, or not work.
Check the earth (ground) point from the battery to frame, plus any other earth points off the loom.

 

[mikecbrxx]

Dug the bike out last night for today's hants/surrey ride out.

Took it for a brief spin last night to get petrol, and after the initial run from the barn to the house it was fine, but after leaving it to get my helmet and gloves, the bike was dead as a dodo.

Apart from the indicator lights on the dash flashing repeatedly, and thats with the ignition off.

Turn the key and absolutely nothing.

I stripped the bike, and pulled all the relays out i could find, blew all the crap out of the joints and reconnected them, and all seemed fine.

Took it out and got petrol, and no problems.

Loaded into the van and onto hindhead this morning, and at the end of the first trail it did exactly the same thing again.

I've stripped the bike again, and still haven't found any damage on the loom.

I see on Advrider that the starter solenoid can give problems similar to my original post, so i'll be changing that.

Has anyone else had problems with their bike? what was the cause?

nathan

Judging by other reports I've seen on ADVRider, the ignition switch has been blamed for this type of problem. Try looking at that, it can be stripped, and maybe re-soldering the connections.

I've replaced mine completely, but that was nothing to do with any problems, and I've never had any like this

 

[Losttheplot]

Judging by other reports I've seen on ADVRider, the ignition switch has been blamed for this type of problem. Try looking at that, it can be stripped, and maybe re-soldering the connections.

I've replaced mine completely, but that was nothing to do with any problems, and I've never had any like this

Cheers mike,

but i've done 2 ignition switches already on this bike.

Basically when they fail the bike goes completely dead.

I was having the indicator lights flash (on the dahboard) when the ignition was turned off.

The same symptoms can be recreated as soon as you connect the battery, but it doesn't last long enough for the full display of lights to come up on the dashboard as it would if you actually connected up the battery.

All battery connections were good and clean. nothing that would really raise any concerns.

Has anyone found the main earth on the bike yet? i've been having a good look around while doing other jobs on it, and not found anything that looks like it could be the likely culprit.

Still stumped....

 

[Losttheplot]

Update.

I found the main earth for the frame bolted to the engine block. This is loacted behind the rectifier.

I removed, cleaned it and replaced it, but there were not signs at all of any corrosion.

I've also replaced the starter solenoid. This did have signs of corrosion where the terminals exit the unit. It's now been replaced and everything seems fine again.

 

[mikecbrxx]

I found the main earth for the frame bolted to the engine block. This is loacted behind the rectifier.

I removed, cleaned it and replaced it, but there were not signs at all of any corrosion.

I've also replaced the starter solenoid. This did have signs of corrosion where the terminals exit the unit. It's now been replaced and everything seems fine again.

That's interesting....and well worth remembering ! As I said, seen alot of similar problems reported on ADV.

 

[Losttheplot]

That's interesting....and well worth remembering ! As I said, seen alot of similar problems reported on ADV.

If i get a chance this weekend i might cut the old starter solenoid open and have a look inside to try and understand why it failed.

 

[mikecbrxx]

If i get a chance this weekend i might cut the old starter solenoid open and have a look inside to try and understand why it failed.

Did you manage to find the time ?

 

[Losttheplot]

Did you manage to find the time ?

Hi mike,

I've cut the old solenoid open, and it's actually pretty well sealed against water ingress.

Inside the unit, there didn't appear to be any signs of water getting in.

The main contacts did show signs of heavy pitting.

The only thing i can put it down to is the coil inside breaking down through time and use.

 

[mikecbrxx]

Hi mike,

I've cut the old solenoid open, and it's actually pretty well sealed against water ingress.

Inside the unit, there didn't appear to be any signs of water getting in.

The main contacts did show signs of heavy pitting.

The only thing i can put it down to is the coil inside breaking down through time and use.

Thanks for the feedback!

I assume it was from new so how old was the bike and how many miles had it done?

Same question to anyone else that has had to replace this part......?

 

[Losttheplot]

Thanks for the feedback!

I assume it was from new so how old was the bike and how many miles had it done?

Same question to anyone else that has had to replace this part......?

The bike is a 2007, and it had about 12k miles on it, though most of these were on my local trails, so the bike hasn't had what you'd call "average" use.